Optical ferrules and optical ferrule molds

ABSTRACT

A unitary optical ferrule is molded to include one or more elements for receiving and securing one or more optical waveguides one or more elements for affecting one or more characteristics of light from the optical waveguide while propagating the light within the ferrule. The optical ferrule also includes one or more first alignment features and one or more second alignment features that, when the ferrule is mated with a mating ferrule, each controls alignment of the ferrule with the mating ferrule along three mechanical degrees of freedom. The surface of the optical ferrule can be divided along the thickness axis into a first section and an opposing second section, wherein the first section of the surface includes the receiving and securing elements, the light affecting elements, and the first alignment features and the second section of the surface includes the second alignment features.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation filing of U.S. application Ser. No.16/946,248, filed Jun. 12, 2020, now allowed, which is a divisional ofU.S. application Ser. No. 15/758,743, filed Mar. 9, 2018, issued as U.S.Pat. No. 10,746,942, which is a national stage filing under 35 C.F.R.371 of PCT/US2016/056324, filed Oct. 11, 2016, which claims the benefitof U.S. Provisional Application No. 62/239,996, filed Oct. 12, 2015, thedisclosures of which are incorporated by reference in their entiretiesherein.

TECHNICAL FIELD

This disclosure relates generally to optical ferrules and to molds formaking optical ferrules.

BACKGROUND

Optical connectors can be used for optical communications in a varietyof applications including telecommunications networks, local areanetworks, data center links, and internal links in computer devices.Expanded optical beams may be used in connectors to provide an opticalconnection that is less sensitive to dust and other forms ofcontamination and so that alignment tolerances may be relaxed.Generally, an expanded beam is a beam that is larger in diameter thanthe core of an associated optical waveguide (usually an optical fiber,e.g., a multi-mode fiber for a multi-mode communication system). Theconnector is generally considered an expanded beam connector if there isan expanded beam at a connection point. The expanded beam is typicallyobtained by diverging a light beam from a source or optical fiber. Inmany cases, the diverging beam is processed by optical elements such asa lens or mirror into an expanded beam that is approximately collimated.The expanded beam is then received by focusing of the beam via anotherlens or mirror. Optical connectors including expanded beam opticalconnectors can include optical ferrules that include elements forreceiving and securing optical waveguides, elements for affecting lightfrom the optical waveguides, and features for aligning the opticalferrule to a mating ferrule.

BRIEF SUMMARY

Some embodiments are directed to a molded unitary optical ferrule thatincludes one or more parting line artifacts, the one or more partingline artifacts including a parting line artifact extending substantiallyaround an external perimeter of the unitary ferrule. The parting lineartifacts divide the surface of the optical ferrule along a thicknessaxis into a first section and an opposing second section. The firstsection of the surface includes one or more elements configured forreceiving and securing a optical waveguide, one or more elementsconfigured for affecting one or more characteristics of light from theoptical waveguide while propagating the light within the unitary ferruleand one or more first alignment features that, when the ferrule is matedwith a mating ferrule, control translation of the ferrule along a firstlateral axis orthogonal to the thickness axis, translation of theferrule along a second lateral axis orthogonal to both the thicknessaxis and the first lateral axis, and rotation of the ferrule around thethickness axis. The second section includes at least one secondalignment feature that, when the ferrule is mated with a mating ferrule,controls translation of the ferrule along the thickness axis, androtation of the ferrule around the first and second lateral axes.

According to some embodiments, a molded unitary optical ferrule includesone or more parting line artifacts, including a parting line artifactextending substantially around an external perimeter of the unitaryferrule, the parting line artifacts dividing a surface of the opticalferrule along a thickness axis into a first section and an opposingsecond section. The ferrule includes one or more elements configured forreceiving and securing an optical waveguide, one or more elementsconfigured for affecting one or more characteristics of light from theoptical wave guide while propagating the light within the unitaryferrule, and at least one planar surface configured to make contact witha planar mating surface of a mating ferrule during mating of theferrule. The ferrule also includes one or more alignment features that,when the ferrule mates with the mating ferrule, primarily controlrotation of the ferrule around the thickness axis, translation of theferrule along a first lateral axis orthogonal to the thickness axis, andtranslation of the ferrule along a second lateral axis orthogonal to thethickness axis and to the first lateral axis. The first section of theferrule contains the one or more elements configured for receiving andsecuring an optical waveguide, the one or more elements configured foraffecting one or more characteristics of light, and the alignmentfeatures and the second section of the ferrule includes the planarsurface.

In some embodiments, a molded unitary optical ferrule includes one ormore parting line artifacts, including a parting line artifact extendingsubstantially around an external perimeter of the unitary ferrule, theparting line artifacts dividing a surface of the optical ferrule along athickness axis into a first section and an opposing second section. Theferrule includes one or more elements configured for receiving andsecuring an optical waveguide, one or more elements configured foraffecting one or more characteristics of light from the opticalwaveguide while propagating the light within the unitary ferrule, asliding surface that, during mating of the ferrule and a mating ferrule,facilitates sliding of the ferrule against a sliding surface of themating ferrule along a ferrule mating axis, when the ferrule is matedwith the mating ferrule, the sliding surface is configured to controlrotation of the ferrule around the ferrule mating axis, translation ofthe ferrule along a thickness axis orthogonal to the ferrule matingaxis, and rotation of the ferrule around a lateral axis orthogonal tothe ferrule mating axis and the thickness axis, and one or morealignment features that, when the ferrule is mated with the matingferrule, primarily control translation of the ferrule along the ferrulemating axis, translation of the ferrule along the lateral axis, androtation of the ferrule around the thickness axis. The first section ofthe surface includes the receiving and securing elements, the lightaffecting elements, and the alignment features and the second section ofthe surface includes the sliding surface.

Some embodiments are directed to an injection mold that includes a firstmold side and a second mold side that fit together to define a cavityfor molding a unitary optical ferrule, and configured to separate alonga parting axis. The unitary optical ferrule is molded with a thicknessaxis parallel to the parting axis. The first side of the mold includesfirst mold features configured to mold: a plurality of first elementsconfigured for receiving and securing an optical waveguide and foraffecting one or more characteristics of light from the optical waveguide while propagating the light within the unitary ferrule and one ormore first alignment features that, when the ferrule is mated with amating ferrule, control translation of the ferrule along a first lateralaxis orthogonal to the thickness axis, translation of the ferrule alonga second lateral axis orthogonal to both the thickness axis and thefirst lateral axis, and rotation of the ferrule around the thicknessaxis. The second mold side includes second mold features configured tomold one or more second alignment features that, when the ferrule ismated with a mating ferrule, control translation of the ferrule alongthe thickness axis, and rotation of the ferrule around the first andsecond lateral axes.

Embodiments are directed to an injection mold including a first moldside and a second mold side that fit together to define a cavity formolding a unitary optical ferrule and configured to separate along aparting axis. The unitary optical ferrule is molded with a thicknessaxis parallel to the parting axis. The first mold side has first moldfeatures configured to mold: a plurality of first elements configuredfor receiving and securing an optical wave guide and for affecting oneor more characteristics of light from the optical waveguide whilepropagating the light within the unitary ferrule and one or more firstalignment features that, when the ferrule is mated with a matingferrule, control translation of the ferrule along a first lateral axisorthogonal to the thickness axis, translation of the ferrule along asecond lateral axis orthogonal to both the thickness axis and the firstlateral axis, and rotation of the ferrule around the thickness axis. Thesecond mold side includes second mold features configured to mold one ormore second alignment features that, when the ferrule is mated with amating ferrule, control translation of the ferrule along the thicknessaxis, and rotation of the ferrule around the first and second lateralaxes.

Some embodiments involve an optical ferrule that includes one or morereceiving elements and one or more light affecting elements. Eachreceiving element is configured for receiving and securing an opticalwaveguide. Each light affecting element includes a light redirectingfeature comprising a curved lens in an optical path of light from theoptical waveguide, the receiving element configured to align thewaveguide with the lens, and a planar region at least partiallysurrounding the lens and comprising a first reference surface for thelens. The light affecting element includes an intermediate surface thatextends between the receiving element and the light redirecting featureand comprising a second reference surface, wherein the first referencesurface is disposed at a predetermined angle with respect to the secondreference surface, the angle determining a positional relationshipbetween the lens and the waveguide.

According to some embodiments, an optical ferrule includes one or morereceiving elements and one or more light affecting elements. Eachreceiving element is configured for receiving and securing an opticalwaveguide. Each light affecting element comprises a light redirectingfeature. Each light redirecting feature comprises a curved lens in anoptical path of light from the optical waveguide, the receiving elementconfigured to align the waveguide with the lens and a planar region atleast partially surrounding the lens the planar region comprising afirst reference surface for the lens. The first reference surface isdisposed at an angle with respect to a second reference surface of theoptical ferrule; the angle determines a positional relationship betweenthe lens and the waveguide.

Some embodiments involve an injection mold. The mold includes a firstmold side and a second mold side that fit together to define a cavityfor molding a unitary optical ferrule. The cavity is configured toseparate along a parting axis, the unitary optical ferrule being moldedwith a thickness axis parallel to the parting axis. The first mold sideincludes mold features configured to mold one or more light affectingelements, each light affecting element a light redirecting featurecomprising a curved lens in an optical path of light from the opticalwave guide, the receiving element configured to align the waveguide withthe lens and a planar region at least partially surrounding the lens andcomprising a first reference surface for a position of the lens. Thefirst reference surface is disposed at an angle with respect to a secondreference surface of the optical ferrule that determines a positionalrelationship between the lens and the waveguide.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1A illustrates a first side of the optical ferrule in accordancewith some embodiments;

FIG. 1B illustrates a second side of the ferrule of FIG. 1A;

FIG. 1C illustrates a flash parting line artifact;

FIG. 1D illustrates a step parting line artifact;

FIGS. 2A and 2B illustrate first and second sides of a mold according tosome embodiments.

FIGS. 3A through 3D show a unitary optical ferrule made using the moldof FIGS. 2A and 2B;

FIGS. 4A and 4B illustrate first and second sides of a mold according tosome embodiments;

FIG. 4C shows a second mold side that includes mold features configuredto mold multiple planar surfaces in accordance with some embodiments

FIGS. 5A through 5D show first and second sides of a unitary opticalferrule made using the mold of FIGS. 4A and 4B;

FIG. 5E illustrates the second side of a unitary optical ferrule madeusing the second mold side shown in FIG. 4C;

FIGS. 6A and 6B illustrate first and second sides of a mold according tosome embodiments;

FIGS. 7A and 7B show first and second sides of a unitary optical ferrulemade using the mold of FIGS. 6A and 6B;

FIG. 7C is a view of a perimeter parting line artifact of the opticalferrule of FIGS. 7A and 7B;

FIGS. 8A and 8B illustrate first and second sides of a mold according tosome embodiments;

FIGS. 9A and 9B show a unitary optical ferrule made using the mold ofFIGS. 8A and 8B;

FIG. 10 depicts mated unitary optical ferrules having multiple parallelplanar surfaces in accordance with some embodiments;

FIGS. 11A through 11C illustrate first and second sides of a moldaccording to some embodiments; and

FIGS. 12A through 12E show a unitary optical ferrule made using the moldof FIGS. 11A through 11C.

The figures are not necessarily to scale. Like numbers used in thefigures refer to like components. However, it will be understood thatthe use of a number to refer to a component in a given figure is notintended to limit the component in another figure labeled with the samenumber.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Optical connectors including expanded beam optical connectors caninclude optical ferrules (also referred to herein as “light couplingunits” or “LCUs”) that are formed as unitary, molded structures. Someembodiments described herein involve molded optical ferrules and moldsfor making optical ferrules. Molding ferrules involves the use of twoprimary mold parts which are referred to herein as the “first mold side”and the “second mold side”. The first mold side includes first moldfeatures configured to mold a first set of the features of the opticalferrule. The second mold side includes second mold features configuredto mold a second set of the features of the optical ferrule. When themold is operated, the two halves are brought together along what isreferred to herein as the “parting axis”, the first side and the secondside define a cavity for molding a unitary optical ferrule. A flowablemold material is injected or otherwise placed into the cavity andhardens, e.g., due to cooling of the mold material, to form the unitaryferrule. The mold halves are then separated along the parting axis toallow the ferrule to be removed. Some materials useful for moldedferrules include thermoplastic and thermosetting polymers, ceramics,metals, glasses, etc.

FIG. 1A and FIG. 1B are diagrams of a unitary optical ferrule 100. Aunitary optical ferrule is a single piece structure that includes one ormore elements for receiving and securing a waveguide, one or moreelements for affecting light from the waveguide, and one or morealignment features.

FIG. 1A illustrates a first side 101 of the optical ferrule 100 and FIG.1B illustrates a second side 102 of the ferrule 100. For purposes ofdiscussion and without limitation to any particular orientation of theferrule, the first side 101 may be designated as the top side and thesecond side 102 as the bottom side. The optical ferrule 100 includes atleast one element 103 for receiving and securing an optical waveguide104 and at least one element 105 for affecting one or morecharacteristics of light from the optical wave guide 104 whilepropagating the light within the optical ferrule 100. The opticalferrule 100 includes one or more alignment features 111-114 for aligningthe optical ferrule 100 with a mating optical ferrule (not shown inFIGS. 1A and 1B).

Alignment of the optical ferrule 100 with the mating optical ferrule isachieved by controlling six mechanical degrees of freedom in threedimensions, the six mechanical degrees of freedom being translationalong and rotation around each of three orthogonal axes 121, 122, 123.For purposes of discussion, axis 121 is referred to herein as the firstlateral axis, axis 122 is referred to herein as the second lateral axis,and axis 123 is referred to as the thickness axis. Axis 121 can be theferrule mating axis. The six mechanical degrees of freedom controlledafter mating the ferrule to a mating ferrule include translation alongthe first lateral axis 121, translation along the second lateral axis122, translation along the thickness axis 123, rotation around the firstlateral axis 121, rotation around the second lateral axis 122, androtation around the thickness axis 123. In the example shown in FIGS. 1Aand 1B, when the ferrule 100 is mated with a mating ferrule, forwardstops 111 contact forward stops of the mating ferrule to controltranslation along the first lateral axis 121; pin 112 of ferrule 100engages with a socket of the mating ferrule and socket 113 of ferrule100 engages with a pin of the mating ferrule to control translation ofthe ferrule 100 along the second lateral axis 122. The forward stops111, and/or the pin 112 and socket 113 may be used to control therotation of the ferrule around the thickness axis 123. When the ferrule100 is mated with a mating ferrule, the surface 114 of ferrule 100engages with a surface of the mating ferrule to control translation ofthe ferrule 100 along the thickness axis 122, rotation of the ferrulearound the first lateral axis 121, and rotation of the ferrule aroundthe lateral 122 axis. In some embodiments, the socket 113 is formed byat least a portion of a hole that extends through the thickness of theferrule 100.

Additional information regarding optical ferrules having the alignmentfeatures disclosed herein is provided in commonly owned and concurrentlyfiled U.S. Patent Application Ser. 62/240,069, having the title “OpticalFerrules,” which is incorporated herein by reference.

The error in alignment of the mold sides can be significant, e.g., onthe order of about 10 μm or more. If the receiving and securingelements, the light affecting elements, and mechanical alignmentfeatures are not molded by a single side of the mold, the receiving andsecuring elements and the light affecting elements may be misalignedwith the alignment features. When such a defective ferrule is mated witha mating ferrule, the alignment features cause the receiving andsecuring elements and the light affecting elements to be improperlyaligned with the mating ferrule, thereby increasing the opticalinsertion loss of the connector.

Some embodiments disclosed herein involve a mold for molding an opticalferrule, the mold including a first mold side and a second mold sidethat fit together to define a cavity for molding a unitary opticalferrule. The unitary optical ferrule is molded with a thickness axisparallel to the parting axis of the mold. In some embodiments, the firstmold side may comprise a single mold insert that includes first moldfeatures configured to mold one or more elements configured forreceiving and securing an optical waveguide and one or more elementsconfigured for affecting characteristics of light from the opticalwaveguide while propagating the light within the unitary ferrule. Thefirst mold features are also configured to mold one or more firstalignment features that, when the ferrule is mated to a mating ferrule,primarily control translation of the ferrule along lateral axesorthogonal to the thickness axis, and rotation of the ferrule around thethickness. The second mold side includes second mold features that areconfigured to mold one or more second alignment features that, when theferrule is mated with a mating ferrule, primarily control translation ofthe ferrule along the thickness axis, and rotations of the ferrulearound the lateral axes.

In some embodiments, the second alignment feature includes a planarsurface that is normal to the parting axis of the mold. In theseembodiments, the molded ferrule can be insensitive to nominalmisalignment of the mold sides. In some embodiments, one of the lateralaxes is a mating axis of the ferrule.

Some embodiments disclosed herein are directed to a unitary opticalferrule made by the mold sides discussed above, the optical ferrulemolded with a thickness axis parallel to the mold parting axis, andincluding one or more elements configured for receiving and securing anoptical waveguide and one or more elements for affecting one or morecharacteristics of light from the optical waveguide while propagatingthe light within the unitary ferrule. The optical ferrule includes oneor more first alignment features that, when the ferrule is mated with amating ferrule, control translation of the ferrule along lateral axesorthogonal to the thickness axis, and rotation of the ferrule around thethickness axis. The optical ferrule includes at least one secondalignment feature that, when the ferrule is mated with a mating ferrule,controls translation of the ferrule along the thickness axis, rotationof the ferrule around the lateral axes. The surface of the opticalferrule can be divided along the thickness axis into a first section ofthe surface and a second section of the surface. The first section ofthe ferrule contains the receiving and securing elements, the lightaffecting elements, and the first alignment features and the secondsection of the ferrule includes the second alignment features and thelight transmitting region through which light is coupled to a matedferrule. In some embodiments the first section is molded by the firstside of a mold, and the second section molded by the second side of amold; a mold parting line artifact separates the first section of thesurface from the second section of the surface. Parting line artifactsare features in the molded part that occur due to the misalignment orimperfect contact between the sides of the mold at the parting line. Theartifact may take the form of a small step or molding flash.

FIG. 1C illustrates a portion of a cross sectional view of first 161 andsecond 162 sides of a mold and molded material 170 between the first andsecond mold sides 161, 162. A flash parting line artifact 171 occurswhere the molded material 170 penetrates a small gap between the moldsides 161, 162. FIG. 1D illustrates a portion of a cross sectional viewof first 181 and second 182 sides of a mold 180 with a mold material 190between the first and second mold sides 181, 182. A flash parting lineartifact 191 occurs where the mold material 190 penetrates a small gapbetween the mold sides 181, 182. A step parting line artifact 192 occurswhere the second side of the mold includes a vertical wall that isslightly misaligned with the vertical wall of the first side and themolded material penetrates a small gap between mold sides 181, 182.

FIGS. 2A and 2B illustrate first and second sides 201, 202 of a mold,respectively, according to some embodiments. Note that the figures ofthe mold sides presented herein are schematic and are intended tofacilitate understanding of the various embodiments. In these schematicdiagrams, some features that are not necessary to understand concepts ofthe embodiments have been omitted, e.g., extraction pins, optionalmultiple inserts, and multiple cavities, etc. Those skilled in the artof injection molding will understand that these features may be presentin actual molds. FIGS. 3A through 3D show a unitary optical ferrule 300made using the mold of FIGS. 2A and 2B. The first mold side 201 includesfirst mold features 203, 205, 211, 212, 213 and the second mold side 202includes second mold feature 214 and 217. Mold features 203 of mold side201 are configured to mold one or more elements 303, e.g., grooves, ofthe optical ferrule 300 configured for receiving and securing an opticalwaveguide. Mold features 205 are configured to mold one or more elements305 of the optical ferrule 300 configured for affecting characteristicsof light from the optical waveguide while propagating the light withinthe optical ferrule 300. Although optical ferrule 300 includes multiplereceiving and securing elements 303 and multiple light affectingelements 305, some unitary optical ferrules can include a singlereceiving and securing element 303 and a single light affecting element305.

The first mold side 201 includes mold features 211, 212, 213 configuredto mold one or more first alignment features 311, 312, 313. When matedwith a mating optical ferrule (not shown), alignment features 311 of theoptical ferrule 300 control translation of the ferrule 300 along a firstlateral axis 121. Features 311 shown in the example optical ferrule 300of in FIGS. 3A through 3D are forward stops that engage with forwardstops of a mating ferrule to set the mated distance between lightaffecting elements of the optical ferrule and light affecting elementsof the mating ferrule. The forward stops 311, when engaged with forwardstops of the mating ferrule, also control rotation of the opticalferrule 300 around the thickness axis 123. In this example, the forwardstops 311 are located along a line 126 on the horizontal mating surface314, the line 126 passing through the centers of the optical beams. Theforward stops 311 are formed by the first side 201 of the mold.

Mold features 212, 213 are configured to mold alignment features 312,313 in the optical ferrule 300. In the example ferrule shown in FIGS. 3Athrough 3D, alignment feature 312 is a pin that fits into a compatiblesocket of a mating ferrule. Alignment feature 313 is a socket. A portion313 a of the socket is molded by mold feature 213 a and is configured toreceive a compatible pin of the mating ferrule. The pin and socket 312,313 control translation of the optical ferrule 300 along the secondlateral axis 122 and may also control rotation of the optical ferrulearound the thickness axis 123. Feature 312 may be designed such thatonly the sides of the pin 312 can come into contact with the matingsocket, providing a lateral stop on either side of the pin 312 andthereby controlling translation along the second lateral axis 122. Thepin 312 is designed to be slightly narrower that the socket 313 to allowfor manufacturing tolerances. Optionally, compliant features (not shown)could be designed into the pin and/or socket to allow for manufacturingtolerances. In some embodiments, the compliant features may provideflexible alignment. The pin or the socket, or both, can be fitted withcompliant side features that facilitate centering the pin in the socket.

In some embodiments, the first side of the mold 201 is a single, unitarymold insert configured to mold the first mold features, thereby assuringconsistent and accurate alignment of the receiving and securingelements, light affecting elements, and first alignment features in themolded ferrules.

The second mold side 202 includes at least one mold feature 214 bconfigured to mold at least one second alignment feature 314 that, whenthe ferrule 300 is mated with a mating ferrule, controls translation ofthe ferrule 300 along the thickness axis 123, rotation of the ferrule300 around the first lateral axis 121, and rotation of the ferrule 300around the second lateral axis 122. In the example ferrule 300 shown inFIGS. 3A through 3D, alignment feature 314 is a planar surface thatcontrols three degrees of mechanical freedom of the optical ferrule.When making the ferrule 300, mold sides 201 and 202 are brought togetherthrough relative motion of the mold sides 201, 202 along the partingaxis 125. Surface 214 b is preferably normal to the direction ofrelative motion of the first and second mold sides (parting axis 125),and being planar, is insensitive to lateral misalignment of the moldsides.

The top and bottom surface 390 of optical ferrule 300 is formed by thefirst mold side 201 and the second mold side 202. The complete surface390 can be divided into a first section 391 which is molded by the firstmold side 201 and a second section 392 opposite the first section 391that is molded by the second mold side 202. The first section 391 of thesurface 390 of the ferrule 300 includes those features 303, 305, 311,312, 313 that are molded by mold features 203, 205, 211, 212, 213 of thefirst side 201 of the mold. The second section 392 of the surface 390 ofthe ferrule 300 includes the features 314 and 317 that are molded by themold feature 214 b and 217 of the second side 202 of the mold.

Optical ferrules as described herein may have complex shapes includingholes that extend through the ferrule, such as socket 313. The surfaceof an optical ferrule includes the surface portions within the holes,e.g., the surface 390 includes the surface within the socket 313.

The parting lines of the mold are the locations of edges of the moldwhere the first and second sides of the mold come together. During themolding process, parting line artifacts are formed on the surface of themolded part at locations where the parting lines of the two sides of themold are in contact with the material being molded. Referring again toFIGS. 2A and 2B, a first parting line occurs where the edge of surface231 a of the first mold side 201 contacts surface 231 b of the secondmold side 202. This parting line continues where the edge of surface 214a contacts surface 214 b. A secondary parting line occurs where the edgeof surface 232 a of the first side 201 contacts surface 231 b of thesecond side 202. The first parting line extends around a perimeter ofthe mold, separating the mold halves, and is referred to as theperimeter parting line. A two part mold as shown in FIGS. 2A and 2B hasone perimeter parting line and may have one or more secondary partinglines disposed within the perimeter parting line.

The parting line between surfaces 231 a and 231 b forms a parting lineartifact 331 around a perimeter of the optical ferrule 300. A secondparting line artifact 332 is formed between the surface 232 a of theshut off plug and surface 231 b. In this example, the second partingline artifact 332 is disposed within the perimeter parting line artifact331.

In an as-molded ferrule, each parting line artifact may be a closedshape, however, subsequent processing or damage to the as-molded ferrulecan remove portions of the parting line artifact resulting in gaps inthe parting line artifact. For example, the as-molded ferrule 300 shownin FIGS. 3A and 3B and the as-molded ferrule 500 shown in FIGS. 5A and5B include a runner 395, 595 that provides for the injection of moldingmaterial and that is removed in a subsequent processing step aftermolding. In general, the perimeter parting line artifact encloses theperimeter of the as-molded ferrule 300, 500 except at the injectionsite, commonly called the gate. Removal of the runner 395, 595 causes asmall gap in the perimeter parting line artifact. One or more partingline artifacts, whether closed or open shapes, divide the surface of theferrule into the first section of the ferrule surface and the secondsection of the ferrule surface opposite the first section.

Optical ferrules according to various embodiments can include moldedfeatures that provide for propagation of light within the ferrule andbetween the ferrule and a mating ferrule that is aligned with theferrule. For example, the light affecting elements 305 may compriselenses or mirrors and may affect one or more of a direction and adivergence of the light propagating in the unitary ferrule 300. In someembodiments, the second side of the mold 202 includes a feature 217configured to mold an optical output surface 317, wherein the lightpropagating in the optical ferrule 300 exits the optical ferrule 300after being transmitted by the optical output surface 317. In someembodiments, the one or more surfaces that form the second alignmentfeature 314 are coated with an optical antireflection coating.

The second alignment feature 314 can be a planar surface as shown inFIGS. 3B and 3D or may include multiple planar surface segments 524 asshown in FIG. 5E. However, the second alignment feature need not beplanar and may comprise any surface that allows the ferrule 300 to sliderelative to and in contact with a compatible mating surface of a matingferrule.

In hermaphroditic ferrule embodiments illustrated herein, the ferruleand the mating ferrule include both male and female components and aresubstantially identical. However, it is not necessary for the ferruleand the mating ferrule to be identical or hermaphroditic. For example,in some embodiments the second alignment feature of the ferrule may be aconvex surface that is configured to slide against a concave surface ofa mating connector.

The first alignment features of the ferrule 300 include a pin 312disposed at a mating edge of the ferrule 300, e.g., extending from thecenter of the mating edge, wherein the pin 312 is configured to engage amating socket of a mating ferrule. In some embodiments, the pin 312 canbe configured to control translation of the ferrule along both the firstlateral axis 121 and the second lateral axis 122. In other embodiments,a central recess between the mating socket and the pin limits contactbetween the pin and mating socket to the lateral surfaces of the pin andmating socket. In some embodiments, the central recess providessufficient clearance between the pin 312 and its mating socket such thatthe forward stop features 311, rather than pin 312, control translationalong the first lateral axis 121. The pin 312 shown in FIGS. 3A through3D includes a rounded leading edge, however, in some embodiments the pinmay be square, tapered, or angled and the socket of the ferrule and amating ferrule may have a complementary square, tapered, or angledshape.

In some embodiments, the first side of the mold 201 may include a moldfeature 218 configured to form a spade portion 318 at a mating end offerrule 300. The spade 318 may be configured to facilitate mating of theoptical ferrule 300 to a mating optical ferrule with sufficientclearance such that the spade 318 does not significantly controlmechanical degrees of freedom when the optical ferrule 300 is mated witha mating ferrule. In some embodiments, as shown in FIGS. 3A through 3D,the pin 312 extends from the spade 318. Sufficient clearance can also beprovided by mold features 213 a, 212 to allow for flash at the edges offeatures 313 a, 312 configured to receive a pin and a socket of a matingferrule, respectively. In some embodiments, the mating end of the spademay not include a pin (e.g., see FIGS. 5A through 5D).

FIGS. 4A and 4B illustrate first and second sides 401, 402 of a moldaccording to some embodiments. FIGS. 5A through 5D show first and secondsides of a unitary optical ferrule 500 made using the mold of FIGS. 4Aand 4B. The first mold side 401 includes first mold features 403, 405,411, 412, 413 and the second mold side 402 includes second mold feature414. Mold features 403 are configured to mold elements 503, e.g. v-, u-,or y-grooves, of the optical ferrule 500 which receive and secure anoptical waveguide. Mold features 405 are configured to mold one or moreelements 505 of the optical ferrule 500 that affect characteristics oflight from the optical wave guide while propagating the light within theunitary ferrule 500. For example, the light affecting elements 505 maycomprise lenses or mirrors and may affect one or more of a direction anda divergence of the light propagating in the unitary ferrule 500.Although optical ferrule 500 includes multiple receiving and securingelements 503 and multiple light affecting elements 505, some unitaryoptical ferrules can include a single receiving and securing element 503and a single light affecting element 505.

The first mold side 401 includes mold features 411, 412, 413 configuredto mold first alignment features 511, 512, 513 of the unitary ferrule500. One or more mold features 411 are configured to mold one or morealignment features 511 in the ferrule 500 that, when the ferrule 500 ismated with a mating ferrule (not shown), control translation of theferrule 500 along a first lateral axis 121. In the embodiment shown inFIGS. 5A through 5D, the features 511 comprise forward stops that, whenengaged with forward stops of a mating ferrule, restrict further forwardmotion along the first lateral axis 121. The forward stops 511 alsocontrol rotation of the ferrule 500 around the thickness axis 123.

One or more mold features 412, 413 are configured to mold one or morealignment features 512, 513 in the ferrule 500 that control translationof the ferrule 500 along the second lateral axis 122. In the embodimentof FIGS. 5A through 5D, the optical ferrule 500 includes side arms 512having contact elements 513. After the ferrule 500 mates with a matingferrule, the contact elements 513 of each arm 512 make contact with aside of the mating ferrule. Flexibility in the arms 512 can allow forsubstantial manufacturing tolerances. When mated with a mating ferrule,the contact elements 513 and side arms 512 control translation of theoptical ferrule along the second lateral axis 122 and may also controlrotation of the optical ferrule 500 around the thickness axis 123. Sidearms 512 are flexible, thus the side arms 512 and lateral stops 513limit movement along the second lateral axis 122 but allow some lateralmovement of the ferrule. Flexible side arms 512 facilitate alignment ofthe light affecting elements 505 of the ferrule 500 and the lightaffecting elements of the mating ferrule. In this example, inequilibrium, the forces created by the flexing of the four arms of theferrule 500 and the mating ferrule balance to align the ferrulesrelative to each other. In some embodiments, the ends of the armsprovide forward stops that control translation along the first lateralaxis 121.

The material forming the compliant features and/or the geometry of thecompliant features can be selected to provide a desired alignment forcebetween ferrules. For example, the alignment force provided by thecompliant features can be increased or decreased by choosing a materialfor the compliant features with a higher or lower Young's modulus,respectively. As another example, in embodiments utilizing flexiblearms, the alignment force provided by the flexible arms can be increasedor decreased by choosing larger or smaller cross-sectional areas,respectively, for the flexible arms. Useful alignment forces can beobtained by choosing an injection moldable polymer for both a body ofthe ferrule and the compliant features of the ferrule and by choosing ageometry of the compliant features that can be injection molded alongwith the body of the ferrule. In this way, for example, a unitaryferrule having compliant features that provide a desired alignment forcecan be made in an injection molding process. Additional detailsregarding flexible alignment features are provided in commonly owned andconcurrently filed U.S. Patent Application Ser. 62/240,066, having thetitle “Ferrules, Alignment Frames and Connectors,” which is incorporatedherein by reference.

The second mold side 402 includes at least one mold feature 414configured to mold at least one second alignment feature 514 that, whenthe ferrule 500 is mated with a mating ferrule, controls translation ofthe ferrule 500 along the thickness axis 123, rotation of the ferrule500 around the first lateral axis 121, and rotation of the ferrule 300around the second lateral axis 122. As shown in FIG. 5A through 5D, thesecond alignment feature may comprise a planar surface. When making theferrule 500, mold sides 401 and 402 are brought together along theparting axis 125. Surface 414 is preferably normal to the direction ofthe relative motion of the mold sides (parting axis 125), making itinsensitive to misalignment of the mold sides. Mold feature 417 isconfigured to form an optical window 517, e.g., a recessed opticalwindow, in the planar surface 514. Optical window 517 may be coated withan antireflective coating.

The optical ferrule 500 has a surface 590 that is formed by the firstmold side 401 and the second mold side 402. The surface 590 can bedivided into a first section 591 that includes features 503, 505, 511,512, 513 which are formed by the first mold side 401 and a secondsection 592 that includes features 514 that is formed by the second moldside 402.

Referring again to FIGS. 4A-4B, a parting line occurs where the edge ofsurface 431 a of the first mold side 401 contacts surface 431 b of thesecond mold side 402. The parting line extends around a perimeter of themold, separating the mold sides.

The parting line between surfaces 431 a and 431 b forms parting lineartifact 531 that extends around a perimeter of the as-molded opticalferrule 500. The parting line artifact 531 divides the surface 590 ofthe ferrule 500 into the first section 591 and the second section 592opposite the first section 591. The first section 591 includes thereceiving and securing elements 503, the light affecting elements 505,and one or more first alignment features 511, 512, 513. After theferrule 500 is mated with a mating ferrule, the first alignment features511, 512, 513 control translation of the ferrule along the first lateralaxis 121, translation of the ferrule along the second lateral axis 122,and rotation of the ferrule 500 around the thickness axis 123.

The second section 592 of the surface 590 of the optical ferrule 500includes at least one second alignment feature 514. After the ferrule500 is mated with a mating ferrule, the second alignment feature 514,which may be a planar surface as shown in FIG. 5B, controls translationof the ferrule along the thickness axis 123, rotation of the ferrule 500around the first lateral axis 121, and rotation of the ferrule 500around the second lateral axis 122. Mold feature 417 is configured toform an optical window 517, e.g., a recessed optical window, in theplanar surface 514.

In some embodiments, a mold feature 418 is configured to mold a spade518 of the optical ferrule 500. The spade 518 may be configured tofacilitate mating of the optical ferrule 500 to a mating optical ferrulewith sufficient clearance such that the spade 518 does not significantlycontrol mechanical degrees of freedom when the optical ferrule 500 ismated with a mating ferrule. Sufficient clearance can be provided byfeatures 419 in the second side 402 of the mold for the spade of amating ferrule, allowing for flash at the edges of the spade.

An alternative to a planar surface 314, 514 illustrated in FIGS. 3B and5B is the use channels, bumps and/or rails that provide multiple planarsurfaces that mate against a similar surface or a single planar surfaceof a mating ferrule. The multiple planar surfaces may be multipleco-planar surfaces or multiple parallel surfaces. The total surface areaof the planar surface regions is large enough to accommodate any matingforces between ferrules. FIG. 4C illustrates the second side 422 of amold having a surface 415 that includes mold features 424 configured tomold a surface 515 with multiple channels 524 of the optical ferrule 501as shown in FIG. 5E. The lands of the channels provide multiple planarsurfaces 524 a. In various embodiments, the channels 524 may be disposedon one side or both sides of the optical output window 517. The channels524 may be substantially parallel to the edges of the optical outputwindow 517 and/or may be disposed at an angle to the optical outputwindow 517. The flush mating of the planar surfaces 524 a with a matingferrule determines three degrees of freedom: translation along thethickness axis 123, rotation around the first lateral axis 121, androtation around the second lateral axis 122. The three remaining degreesof freedom: translation along the first lateral axis 121, translationalong the second lateral axis 122, and rotation around the thicknessaxis 123 are all determined by mating features in the first side of themold, which also contains the features for molding the optical elements.

FIGS. 6A and 6B illustrate first and second sides 601, 602 of a moldaccording to some embodiments. FIGS. 7A and 7B show first and secondsides of a unitary optical ferrule 700 made using the mold of FIGS. 6Aand 6B. The first mold side 601 includes first mold features 603, 605,612 and the second mold side 602 includes second mold feature 614. Moldfeatures 603 are configured to mold elements 703, e.g. grooves, of theoptical ferrule 700 which receive and secure an optical waveguide. Moldfeatures 605 are configured to mold one or more elements 705 of theoptical ferrule 700 that affect characteristics of light from theoptical wave guide while propagating the light within the unitaryferrule 700. For example, the light affecting elements 705 may compriselenses or mirrors and/or may affect one or more of a direction and adivergence of the light propagating in the unitary ferrule 700. Althoughoptical ferrule 700 includes multiple receiving and securing elements703 and multiple light affecting elements 705, some unitary opticalferrules can include a single receiving and securing element and asingle light affecting element.

The first mold side 601 includes mold features 612, 613 that areconfigured to mold first alignment features 712, 713 of the unitaryoptical ferrule 700. When the ferrule 700 is mated with a mating ferrule(not shown), the first alignment features 712, 713 control translationof the ferrule 700 along the first lateral axis 121, translation of theferrule along the second lateral axis 122, and rotation of the ferrule700 around the thickness axis 123. Alignment features 712, 713 in theferrule 700 comprise a pointed pin 712 and a pointed socked 713. Pin 712is configured to fit into a compatible socket of a mating ferrule, e.g.a socket similar in shape to socket 713. Socket 713 is configured toreceive a compatible pin of a mating ferrule, e.g. a pin similar inshape to pin 712.

The second mold side 602 includes at least one mold feature 614configured to mold a second alignment feature 714 that, when the ferrule700 is mated with a mating ferrule, controls translation of the ferrule700 along the thickness axis 123, rotation of the ferrule 700 around thefirst lateral axis 121, and rotation of the ferrule 700 around thesecond lateral axis 122. As shown in FIG. 7B, the second alignmentfeature 714 may comprise a planar surface. When making the ferrule 700,mold sides 601 and 602 are brought together along the parting axis 125.Surface 614 is preferably normal to the direction of the relative motionof the mold sides, making it insensitive to misalignment of the moldsides. Mold feature 617 is configured to form an optical window 717,e.g., a recessed optical window, in the planar surface 714. Opticalwindow 717 may be coated with an antireflective coating.

The optical ferrule 700 has a surface 790 that is formed by the firstmold side 601 and the second mold side 602. The surface 790 can bedivided into a first section 791 that includes features 703, 705, 712,713 which are formed by the first mold side 601 and a second section 792that includes feature 714 that is formed by the second mold side 602.

Referring again to FIGS. 6A and 6B, a parting line occurs where the edgeof surface 631 a of the first mold side 601 contacts surface 631 b ofthe second mold side 602. The parting line where the edge of surface 631a of the first mold side 601 contacts surface 631 b of the second moldside 602 extends around a perimeter of the mold, separating the moldhalves.

Referring now to FIGS. 6A and 6B and FIGS. 7A and 7B, the parting linebetween surfaces 631 a and 631 b forms parting line artifact 731, shownin more detail in inset FIG. 7C, that extends substantially around aperimeter of the optical ferrule 700. The parting line artifact 731divides the surface 790 of the ferrule 700 into a first section 791 andthe second section 792 opposite the first section 791. The first section791 includes the receiving and securing elements, 703, the lightaffecting elements 705, and one or more first alignment features 712,713. After the optical ferrule is mated with a mating optical ferrule,the first alignment features 712, 713 control three degrees ofmechanical freedom—translation of the optical ferrule along the firstlateral axis 121, translation of the optical ferrule along the secondlateral axis 122, and rotation of the optical ferrule around thethickness axis 123.

The second section 792 of the surface 790 of the optical ferrule 700includes at least one second alignment feature 714. After the ferrule700 is mated with a mating ferrule, the second alignment feature 714,which may be a planar surface as shown in FIG. 7B, controls threedegrees of mechanical freedom: translation of the ferrule 700 along thethickness axis 123, rotation of the ferrule 700 around the first lateralaxis 121, and rotation of the ferrule 500 around the second lateral axis122.

In the examples provided above, when the ferrule is mated with a matingferrule, the bottom surfaces of the ferrules (features 314 of FIG. 3B,514 of FIG. 5B, 515 of FIG. 5E, and 714 of FIG. 7B) slide and arepressed against each other ensuring that the ferrule 300, 500, 501, 700and the mating ferrule are parallel and determining the distance alongthe thickness axis 123 between the receiving and securing elements 303,503, 703 (e.g., v-grooves) and the light affecting elements 305, 505,705 (e.g., mirror lenses) of the ferrule 300, 500, 501, 700 and themating ferrule. Because the surface (or multiple surfaces) 314, 514,515, 714 is/are formed normal to the axis 125 of relative motion of thetwo sides of the mold, it has no critical dependence on the alignment ofthe first and second sides of the mold along the first lateral axis 121and the second lateral axis 122. As previously discussed, surface 314,514, 515, 714 may include an optical window where the light beams exitthe ferrule. The window is made large enough to accommodate anymisalignment in the first and second sides of the mold.

As illustrated by FIGS. 8A-10 , in some embodiments, the mold mayinclude features configured to form multiple parallel planar surfaces onthe second section of the optical ferrule. During mating, each planarsurface provides a sliding surface that slides on a mating surface of amating ferrule. When mated, the multiple planar surfaces controltranslation of the optical ferrule along the thickness axis 123,rotation around the first lateral axis 121, and rotation around thesecond lateral axis 122. In some embodiments, one or more of the planarsurfaces may be textured. In some embodiments, the sliding surface mayinclude grooves wherein multiple coplanar surfaces are formed by thelands between the grooves.

FIGS. 8A and 8B illustrate first and second sides 801, 802 respectively,of a mold, according to some embodiments. FIGS. 9A and 9B show a unitaryoptical ferrule 900 made using the mold of FIGS. 8A and 8B. The firstmold side 801 includes first mold features 803, 805, 811, 812, 813 andthe second mold side 802 includes second mold features 814, 815 b and817. Mold features 803 of mold side 801 are configured to mold one ormore elements 903, e.g., grooves, of the optical ferrule 900 configuredfor receiving and securing an optical waveguide. Mold features 805 ofmold side 801 are configured to mold one or more elements 905 of theoptical ferrule 900 configured for affecting characteristics of lightfrom the optical waveguide while propagating the light within theoptical ferrule 900. Although optical ferrule 900 includes multiplereceiving and securing elements 903 and multiple light affectingelements 905, some unitary optical ferrules can include a singlereceiving and securing element 903 and a single light affecting element905.

The first mold side 801 includes mold features 811, 812, 813 configuredto mold one or more first alignment features 911, 912, 913. When matedwith a mating optical ferrule (not shown), alignment features 911 of theoptical ferrule 900 control translation of the ferrule 900 along a firstlateral axis 121, e.g., the first lateral axis. Features 911 shown inthe example optical ferrule 900 of in FIGS. 9A and 9B are forward stopsthat engage with forward stops of a mating ferrule to set the mateddistance between light affecting elements of the optical ferrule andlight affecting elements of the mating ferrule. The forward stops 911,when engaged with forward stops of the mating ferrule, also controlrotation of the optical ferrule 900 around the thickness axis 123. Theforward stops 911 are formed by the first side 801 of the mold.

Mold features 812, 813 are configured to mold alignment features 912,913 in the optical ferrule 900. In the example ferrule shown in FIGS. 9Aand 9B, alignment feature 912 is a pin that fits into a compatiblesocket of a mating ferrule. Alignment feature 913 is a socket. A portion913 a of the socket is molded by mold feature 813 a and is configured toreceive a compatible pin of the mating ferrule. The pin and socket 912,913 control translation of the optical ferrule 900 along the secondlateral axis 122 and may also control rotation of the optical ferrulearound the thickness axis 123. Feature 912 may be designed such thatonly the sides of the pin 912 can come into contact with the matingsocket, providing a lateral stop on either side of the pin 912 andthereby controlling translation along the second lateral axis 122. Thepin 912 is designed to be slightly narrower that the socket 913 to allowfor manufacturing tolerances. Optionally, compliant features (not shown)could be designed into the pin and/or socket to allow for manufacturingtolerances. In such cases, the pin or the socket, or both, can be fittedwith compliant (e.g. elastic) side features that center the pin in thesocket.

The second mold side 802 includes mold features 814 b and 815 bconfigured to mold parallel planar surfaces 914 b and 915 b as secondalignment features. When the ferrule 900 is mated with a mating ferrule,the second alignment features 914 a, 914 b control translation of theferrule 900 along the thickness axis 123, rotation of the ferrule 900around the first lateral axis 121, and rotation of the ferrule 900around the second lateral axis 122. In the example ferrule 900 shown inFIGS. 9A and 9B, alignment features 914 b and 915 b are parallel planarsurfaces that, when the optical ferrule 900 is mated with a matingferrule, control three degrees of mechanical freedom of the opticalferrule 900. When making the ferrule 900, mold sides 801 and 802 arebrought together through relative motion of the mold sides 801, 802along the parting axis 125. Surfaces 814 a, 814 b, and 815 b arepreferably normal to the direction of relative motion of the first andsecond mold sides (along parting axis 125), and being planar, areinsensitive to lateral misalignment of the mold sides.

The surface 990 of optical ferrule 900 is formed by the first mold side801 and the second mold side 802. The complete surface 990 can bedivided into a first section 991 which is molded by the first mold side801 and a second section 992 opposite the first section 991 that ismolded by the second mold side 802. The first section 991 of the surface990 of the ferrule 900 includes those features 903, 905, 911, 912, 913that are molded by mold features 803, 805, 811, 812, 813 of the firstside 801 of the mold. The second section 992 of the surface 990 of theferrule 900 includes the parallel planar surfaces 914 b, 915 b andoptical output window 917 that are molded by the mold features 814 b,815 b, and 817 of the second side 802 of the mold.

A first parting line occurs where the edge of surface 831 a of the firstmold side 801 contacts surface 831 b of the second mold side 802. Thisparting line continues where the edge of surface 814 a contacts surface814 b. A secondary parting line occurs where the edge of surface 832 aof the first side 801 contacts surface 831 b of the second side 802. Thefirst parting line extends around a perimeter of the mold, separatingthe mold halves, and is referred to as the perimeter parting line. A twopart mold as shown in FIGS. 8A and 8B has one perimeter parting line andmay have one or more secondary parting lines disposed within theperimeter parting line.

The parting line between surfaces 831 a and 831 b forms a parting lineartifact 931 around a perimeter of the optical ferrule 900. A secondparting line artifact 932 is formed between the surface 832 a of theshut off plug 813 and surface 831 b. In this example, the second partingline artifact 932 is disposed within the perimeter parting line artifact931.

The as-molded ferrule 900 shown in FIGS. 9A and 9B includes a runner 995that provides for the injection of molding material and that is removedin a subsequent processing step after molding. FIG. 10 provides a crosssectional view of the ferrule 900 mated with a mating ferrule 901.

In some embodiments, as illustrated by FIGS. 11 through 12 , but alsoapplicable to other molds and ferrules described herein, mold featuresprovide reference planes from which the angular relationships betweenvarious surfaces of a ferrule created using the mold can be determined.

FIGS. 11A through 11C illustrate first and second sides 1101, 1102 of amold according to some embodiments in which alignment features inaddition to the planar mating surface are formed by the second moldside. FIG. 11A provides a perspective view of a first mold side 1101;FIG. 11B provides a perspective view of a second mold side 1102; andFIG. 11C is a more detailed perspective view of the first mold side1101. FIGS. 12A through 12E show a unitary optical ferrule 1200 madeusing the mold of FIGS. 11A through 11C. FIG. 12A is a perspective viewof a first side 1201 of the ferrule 1200; FIG. 12B is a perspective viewof the second side 1202 of the ferrule 1200; FIG. 12C is a more detailedview of the first ferrule side 1201; FIG. 12D is a cross sectional viewof the ferrule 1200 mated with a mating ferrule 1250; FIG. 12E isanother perspective view of the first side 1201 of the ferrule 1200.

The first mold side 1101 includes first mold features 1103, 1105, 1112and the second mold side 1102 includes second mold features 1112, 1113,1114 and 1117. Mold features 1103 of mold side 1101 are configured tomold one or more elements 1203, e.g., grooves, U-shaped, V-shaped, orY-shaped grooves, of the optical ferrule 1200 configured for receivingand securing an optical waveguide. Mold features 1105 are configured tomold one or more light affecting elements 1205 of the optical ferrule1200 configured for affecting characteristics of light from the opticalwaveguide while propagating the light within the optical ferrule 1200.Mold features 1105 include mold features 1105 a, 1106, 1107, 1105 b.Mold feature 1105 a is configured to mold ferrule light redirectingfeature 1205 a. The ferrule light redirecting feature 1205 a includes acurved lens 1206 and a planar surface 1207 disposed proximate to and/orat least partially surrounding the lens 1206. Mold features 1106 and1107, respectively, are configured to mold the curved lens 1206 and aplanar surface 1207. Mold feature 1105 b is configured to mold ferrulefeature 1205 b which is an intermediate surface, e.g., a planar surface,disposed between the receiving element 1203 and light redirectingfeature 1205 a. Optical ferrule 1200 includes multiple receiving andsecuring elements 1203 and multiple light affecting elements 1205,however, some unitary optical ferrules can include a single receivingand securing element and a single light affecting element with anintermediate surface disposed therebetween.

Mold side 1101 also includes mold features 1111 configured to moldalignment feature 1211. Alignment feature 1211 of the optical ferrule1200 is configured to control translation of the ferrule 1200 along afirst lateral axis 121.

The second mold side 1102 includes mold features 1111, 1112, 1113, 1114,1117 configured to mold ferrule features 1211, 1212, 1213, 1214, 1217.When mated with a mating optical ferrule (not shown), alignment features1211 of the optical ferrule 1200 control translation of the ferrule 1200along a first lateral axis 121. Features 1211 shown in the exampleoptical ferrule 1200 of in FIGS. 12A and 12B are forward stops thatengage with forward stops of a mating ferrule to set the mated distancebetween light affecting elements of the optical ferrule and lightaffecting elements of the mating ferrule. The forward stops 1211, whenengaged with forward stops of the mating ferrule, may also controlrotation of the optical ferrule 1200 around the thickness axis 123.

Mold features 1112, 1113 are configured to mold alignment features 1212,1213 in the optical ferrule 1200. Mold side 1101 includes mold feature1112 a comprising spaced apart mold feature portions 1112 a-1 and 1112a-2. Mold side 1102 includes mold feature 1112 b that includes spacedapart mold feature portions 1112 b-1 and 1112 b-2. In the exampleferrule 1200 shown in FIGS. 12A and 12B, alignment feature 1212 is a pinthat fits into a compatible socket of a mating ferrule. Alignmentfeature 1213 is a socket that receives a pin of the mating ferrule. Thepin 1212 includes spaced apart portions 1212 a and 1212 b. The pin 1212and socket 1213 control translation of the optical ferrule 1200 alongthe second lateral axis 122 and may also control rotation of the opticalferrule 1200 around the thickness axis 123. Pin 1212 may be designedsuch that only the sides of the pin 1212 can come into contact with themating socket, providing a lateral stop on either side of the pin 1212and thereby controlling translation along the second lateral axis 122.The pin 1212 is designed to be slightly narrower that the socket 1213 toallow for manufacturing tolerances. Optionally, compliant features (notshown) could be designed into the pin and/or socket to allow formanufacturing tolerances. In some embodiments, the compliant featuresmay provide flexible alignment. The pin or the socket, or both, can befitted with compliant side features that facilitate centering the pin inthe socket.

Mold feature 1117 is configured to mold the planar mating surface 1217of the ferrule 1200. The planar mating surface 1217 controls translationof the ferrule 1200 along the thickness axis 123 and/or rotation of theferrule along the first and second lateral axes 121, 122. Mold feature1114 is configured to mold an optical output window 1214 in the planarmating surface 1217.

Optical ferrules and the molds used to make the optical ferrulesaccording to various embodiments, including those illustrated in FIGS.1-12 above, involve molded features, e.g., plastic molded features,configured to provide for propagation of light within the ferrule andbetween the ferrule and a mating ferrule that is aligned with theferrule. For example, the light affecting elements may comprise lenses,e.g., curved lenses, configured to redirect light propagating in theferrule. As previously described, the optical ferrules can include aplanar mating surface having optical output window that is transparentto the propagating light, wherein the light propagating in the opticalferrule exits the optical ferrule after being transmitted by the opticaloutput window.

The angular relationship of the mold features are controlled so that theresulting molded features of the ferrule are controlled to specifiedtolerances to allow for propagation of light within the ferrule betweenthe waveguide, the light affecting element, and the optical outputwindow. As best seen in FIGS. 11C and 12C, each light redirectingelement 1205 may comprise a curved lens 1206 and at least one planarsurface 1207 that may be proximate to and/or may partially or completelysurround the lens 1206. The planar surface 1207 can be used as a firstreference plane which sets the positional relationship of lens 1206 withother features of the ferrule 1200. For example the first referencesurface 1207 is disposed at an angle with respect to a second referencesurface of the optical ferrule, thus setting the angle of the lensrelative to a feature of the receiving element 1203 and/or thelongitudinal axis of a waveguide received by the receiving element 1203.In some embodiments, the mold features can be configured such that theangle between the first reference surface 1207 and the second referencesurface is controlled to have a variation less than +/−3 degrees, lessthan +/−0.3 degrees, less than +/−0.03 degrees, less than +/−0.003degrees, or even less than +/−0.0003 degrees. Although the lens 1106,1206 and first reference plane 1107, 1207 mold and ferrule features arebest seen in FIGS. 11C and 12C, it will be appreciated that similarfeatures may be employed by any of the light affecting elements of moldsand/or ferrules discussed herein. The angular relationships between thefirst reference plane and one or more second reference planes asdiscussed herein can apply to any of the mold and/or ferruleembodiments.

In some embodiments, the receiving elements may be a grooves, e.g.,V-shaped, U-shaped, or Y-shaped grooves, and the second referencesurface may be the bottoms of the grooves. In some embodiments, e.g., asbest illustrated by FIGS. 11 and 12 , the light affecting element 1205includes an intermediate region 1205 b extending between the receivingelement 1203 and the light redirecting feature 1205 a. The intermediateregion 1205 b comprises the second reference surface. In someimplementations, the entire intermediate region 1205 b may be a planarsurface that provides the second reference surface. The second referencesurface of the intermediate region 1205 b may be substantially parallelto the bottom of the receiving element groove. In some embodiments, aplanar surface, e.g., planar mating surface 1217, is disposed on thesecond side 1202 of the optical ferrule 1200 opposite the first side1201 of the ferrule which includes the receiving 1203 and lightaffecting elements 1205. The planar surface 1217 on the second side ofthe ferrule may be or comprise the second reference surface. Forexample, in some implementations, the second reference surface may bethe planar mating surface and/or may be the optical output window 1214or other feature. The optical output window 1214 is transparent to lightfrom the wave guide. In some embodiments, all or portions of the planarmating surface e.g., portions on either side of the optical window 1214,may be configured to be optically transparent to light. Opticaltransparency of the planar surface 1217 (or portions thereof) facilitatethe use of interferometric analysis to determine angular relationshipsbetween the second reference surface of the planar mating surface, thereceiving element, the intermediate portion, and/or the first referencesurface of the light redirecting feature. The planar mating surface moldfeature 1117 may be formed using any technique that provides opticaltransparency, e.g., grinding, polishing, diamond milling, etc.

In some embodiments, one or more fiducials may be made in the mold side(and may be molded into the ferrule) wherein the fiducials correspond toone or more ferrule features. For example, a mold side may be fabricatedby one or more tools and each fiducial may be a divot (or other feature)that indicates a location of the tool used form a mold feature.

One fiducial may correspond to a plurality of ferrule features or onefiducial may correspond to a single ferrule feature. For example, inimplementations that include multiple light affecting elements, multiplefiducials may be used wherein each of the fiducials corresponds to oneof the light affecting elements. In some embodiments, as shown in FIGS.12C and 12E, two or more fiducials 1221, 1222 may correspond to a lightredirecting feature 1205 a, e.g., each light redirecting feature 1205 amay be disposed between two fiducials 1221, 1222.

According to some implementations, at least one fiducial may correspondto at least a single receiving element. In implementations that includemultiple receiving elements, multiple fiducials may be used, whereineach of the fiducials corresponds to one of the receiving elements. Forexample, as shown in FIGS. 12C and 12E, two or more fiducials 1223, 1224may correspond to one of the receiving elements 1203, e.g., eachreceiving element 1203 may be disposed between two fiducials 1223, 1224.Fiducials that correspond to one feature (or type of feature) may havethe same shape or may differ in shape from fiducials that correspond toanother feature (or type of feature).

Additional information regarding ferrules that may be formed byapproaches described herein and alignment frames and connectors that maybe used with ferrules formed by the disclosed approaches is provided inthe following commonly owned and concurrently filed U.S. patentapplications which are incorporated herein by reference: U.S. PatentApplication Ser. 62/239,998, having the title “Connector with LatchingMechanism”; U.S. Patent Application Ser. 62/240,069, having the title“Optical Ferrules”; U.S. Patent Application Ser. 62/240,066, having thetitle “Ferrules, Alignment Frames and Connectors,”; U.S. PatentApplication Ser. 62/240,008, having the title “Optical Cable Assemblywith Retainer,”; U.S. Patent Application Ser. 62/240,000, having thetitle “Dust Mitigating Optical Connector,”; U.S. Patent Application Ser.62/240,009, having the title “Optical Waveguide Registration Feature,”;U.S. Patent Application Ser. 62/240,010, having the title “OpticalCoupling Device with Waveguide Assisted Registration,”; U.S. PatentApplication 62/240,002, having the title “Optical Ferrules withWaveguide Inaccessible Space,”; U.S. Patent Application 62/240,003having the title “Configurable Modular Connectors,”; and U.S. PatentApplication 62/240,005, having the title “Hybrid Connectors.”

Items described in this disclosure include:

Item 1. A molded unitary optical ferrule comprising:

one or more parting line artifacts, the one or more parting lineartifacts including a parting line artifact extending substantiallyaround an external perimeter of the unitary ferrule, the parting lineartifacts dividing a surface of the optical ferrule along a thicknessaxis into a first section and an opposing second section, wherein

-   -   the first section of the surface includes:        -   one or more elements configured for receiving and securing a            optical waveguide;        -   one or more elements configured for affecting one or more            characteristics of light from the optical waveguide while            propagating the light within the unitary ferrule; and        -   one or more first alignment features that, when the ferrule            is mated with a mating ferrule, control translation of the            ferrule along a first lateral axis orthogonal to the            thickness axis, translation of the ferrule along a second            lateral axis orthogonal to both the thickness axis and the            first lateral axis, and rotation of the ferrule around the            thickness axis; and    -   the second section includes at least one second alignment        feature that, when the ferrule is mated with a mating ferrule,        controls translation of the ferrule along the thickness axis,        and rotation of the ferrule around the first and second lateral        axes.        Item 2. The ferrule of item 1, wherein the first lateral axis is        a ferrule mating axis.        Item 3. The ferrule of any of items 1 through 2, wherein the one        or more parting lines comprise one or more additional parting        lines within the perimeter parting line.        Item 4. The ferrule of any of items 1 through 3, wherein the one        or more characteristics of the light propagating within the        unitary ferrule include one or more of a direction and        divergence of the light.        Item 5. The ferrule of any of items 1 through 4 further        comprising an output surface, the light propagating within the        unitary ferrule exiting the ferrule after being transmitted by        the output surface, the output surface disposed in the second        section.        Item 6. The ferrule of item 5, wherein at least the output        surface is coated with an optical antireflection coating.        Item 7. The ferrule of any of items 1 through 6, wherein the        second alignment feature comprises at least one planar surface.        Item 8. The ferrule of item 7, wherein the at least one planar        surface is a single planar surface.        Item 9. The ferrule of item 7, wherein the at least one planar        surface are multiple parallel planar surfaces.        Item 10. The ferrule of item 7, wherein the at least one planar        surface are multiple coplanar surfaces.        Item 11. The ferrule of item 7 wherein, during mating, the at        least one planar surface slides on a planar surface of a mating        ferrule.        Item 12. The ferrule of item 7, wherein the receiving and        securing elements and the light affecting elements are disposed        on a surface of the ferrule opposite the at least one planar        surface.        Item 13. The ferrule of any of items 1 through 12, wherein the        first alignment features comprise a pin disposed at a mating        edge of the ferrule, the pin configured to engage a mating        socket of the mating ferrule, the pin configured to control one        or more of translation of the ferrule along the second lateral        axis and translation of the ferrule along the first lateral        axis.        Item 14. The ferrule of item 13, wherein the mating socket is        formed by a hole through the thickness direction of the ferrule.        Item 15. The ferrule of item 13, wherein a leading edge of the        pin is rounded.        Item 16. The ferrule of item 13, wherein a leading edge of the        pin is angular.        Item 17. The ferrule of item 13, wherein clearance between a        leading edge of the pin and a mating socket limits contact        between the pin and socket to lateral surfaces of the pin.        Item 18. The ferrule of any of items 1 through 17, further        comprising a spade portion at a mating edge of the optical        ferrule.        Item 19. The ferrule of any of items 1 through 18, wherein the        first alignment features includes a first stop disposed at a        first side of the ferrule and a second stop disposed at a second        side of the ferrule, the first and second stops controlling at        least one of translation of the ferrule along the first lateral        axis and rotation of the ferrule around the thickness axis.        Item 20. The ferrule of item 19, wherein the first alignment        features comprise a first flexible arm disposed at a first side        of the ferrule and a second flexible arm disposed at a second        side of the ferrule, each of the first arm and the second arm        including a contact element, each contact element configured to        engage a side of a the mating ferrule.        Item 21. The ferrule of item 20, wherein engagement of the        contact elements with the sides of the mating ferrule controls        control translations of the ferrule along the second lateral        axis.        Item 22. A molded unitary optical ferrule comprising:

one or more parting line artifacts, including a parting line artifactextending substantially around an external perimeter of the unitaryferrule, the parting line artifacts dividing a surface of the opticalferrule along the thickness axis into a first section and an opposingsecond section;

one or more elements configured for receiving and securing an opticalwave guide;

one or more elements configured for affecting one or morecharacteristics of light from the optical waveguide while propagatingthe light within the unitary ferrule;

at least one planar surface configured to make contact with a planarmating surface of a mating ferrule during mating of the ferrule; and

one or more alignment features that, when the ferrule mates with themating ferrule, primarily control rotation of the ferrule around athickness axis, translation of the ferrule along a first lateral axisorthogonal to the thickness axis, and translation of the ferrule along asecond lateral axis orthogonal to the thickness axis and to the firstlateral axis, wherein the first section of the ferrule contains the oneor more elements configured for receiving and securing the opticalwaveguide, the one or more elements configured for affecting one or morecharacteristics of light, and the alignment features and the secondsection of the ferrule includes the planar surface.

Item 23. The ferrule of item 22, wherein the at least one planar matingsurface comprises a plurality of lands between a plurality of grooves.

Item 24. The ferrule of any of items 22 through 23, wherein the at leastone planar mating surface comprises multiple planar mating surfaces.

Item 25. The ferrule of any of items 22 through 24, wherein the one ormore alignment features comprises a socket formed by a hole through thethickness axis of the ferrule.

Item 26. A molded unitary optical ferrule comprising:

one or more parting line artifacts, including a parting line artifactextending substantially around an external perimeter of the unitaryferrule, the parting line artifacts dividing a surface of the opticalferrule along a thickness axis into a first section and an opposingsecond section;

one or more elements configured for receiving and securing an opticalwaveguide;

one or more elements configured for affecting one or morecharacteristics of light from the optical waveguide while propagatingthe light within the unitary ferrule;

a sliding surface that, during mating of the ferrule and a matingferrule, facilitates sliding of the ferrule against a sliding surface ofthe mating ferrule along a ferrule mating axis, when the ferrule ismated with the mating ferrule, the sliding surface is configured tocontrol rotation of the ferrule around the ferrule mating axis,translation of the ferrule along a thickness axis orthogonal to theferrule mating axis, and rotation of the ferrule around a lateral axisorthogonal to the ferrule mating axis and the thickness axis; and

one or more alignment features that, when the ferrule is mated with themating ferrule, primarily control translation of the ferrule along theferrule mating axis, translation of the ferrule along the lateral axis,and rotation of the ferrule around the thickness axis, wherein the firstsection of the surface includes the receiving and securing elements, thelight affecting elements, and the alignment features and the secondsection of the surface includes the sliding surface.

Item 27. The ferrule of item 26, wherein the sliding surface comprisesmultiple planar surfaces.

Item 28. An injection mold comprising:

a first mold side and a second mold side that fit together to define acavity for molding a unitary optical ferrule, the cavity configured toseparate along a parting axis,

the unitary optical ferrule being molded with a thickness axis parallelto the parting axis,

the first mold side having first mold features configured to mold:

-   -   a plurality of first elements configured for receiving and        securing an optical waveguide and for affecting one or more        characteristics of light from the optical waveguide while        propagating the light within the unitary ferrule; and    -   one or more first alignment features that, when the ferrule is        mated with a mating ferrule, control translation of the ferrule        along a first lateral axis orthogonal to the thickness axis,        translation of the ferrule along a second lateral axis        orthogonal to both the thickness axis and the first lateral        axis, and rotation of the ferrule around the thickness axis;

the second mold side having second mold features configured to mold oneor more second alignment features that, when the ferrule is mated with amating ferrule, control translation of the ferrule along the thicknessaxis, and rotation of the ferrule around the first and second lateralaxes.

Item 29. The injection mold of item 28, wherein the first lateral axisis a mating axis of the optical ferrule.

Item 30. The injection mold of any of items 28 through 29, wherein thesecond mold side includes a feature configured to mold an optical outputsurface.

Item 31. The injection mold of any of items 28 through 30, wherein theone or more second alignment features comprises at least one planarsurface.

Item 32. The injection mold of item 31, wherein the parting axis issubstantially perpendicular to at least one planar surface.

Item 33. The injection mold of any of items 28 through 32, wherein thefirst mold side comprises a unitary mold insert that includes the firstmold features.

Item 34. The injection mold of any of items 28 through 33, wherein theone or more second alignment features is a single planar surface.

Item 35. The injection mold of any of claims 28 through 33, wherein theone or more second alignment features is a multiple parallel planarsurfaces.

Item 36. The injection mold of any of claims 28 through 33, wherein theone or more second alignment features is a multiple coplanar surfaces.

Item 37. The injection mold of any of items 28 through 36, wherein thefirst alignment features comprise a pin disposed at a mating edge of theferrule, the pin configured to control one or both of translation of theferrule along the first lateral axis and translation of the ferrulealong both the second lateral axis.Item 38. The injection mold of item 37, wherein a leading edge of thepin is rounded.Item 39. The injection mold of item 37, wherein a leading edge of thepin is angular.Item 40. The injection mold of any of items 28 through 39, wherein thefirst mold side includes a feature configured to mold a spade portion ata mating edge of the optical ferrule.Item 41. The injection mold of any of items 28 through 40, wherein thefirst alignment features include a first stop disposed at a first sideof the ferrule and a second stop disposed at a second side of theferrule, the first and second stops controlling translation of theferrule along the first lateral axis.Item 42. An optical ferrule comprising:

one or more receiving elements, each receiving element configured forreceiving and securing an optical waveguide; and

one or more light affecting elements, each light affecting elementcomprising:

-   -   a light redirecting feature comprising:        -   a curved lens in an optical path of light from the optical            waveguide, the receiving element configured to align the            waveguide with the lens; and        -   a planar region at least partially surrounding the lens and            comprising a first reference surface for the lens; and    -   an intermediate surface that extends between the receiving        element and the light redirecting feature and comprising a        second reference surface, wherein the first reference surface is        disposed at a predetermined angle with respect to the second        reference surface that determines a positional relationship        between the lens and the waveguide.        Item 43. The optical ferrule of item 42, wherein variation in        the angle is controlled to less than +/−3 degrees.        Item 44. The optical ferrule of item 42, wherein variation in        the angle is controlled to less than +/−0.3 degrees.        Item 45. The optical ferrule of item 42, wherein variation in        the angle is controlled to less than +/−0.03 degrees.        Item 46. The optical ferrule of item 42, wherein variation in        the angle is controlled to less than +/−0.003 degrees.        Item 47. The optical ferrule of item 42, wherein variation in        the angle is controlled to less than +/−0.0003 degrees.        Item 48. The optical ferrule of item 42, wherein the        intermediate surface is a planar surface.        Item 49. The optical ferrule of any of items 42 through 48,        wherein the intermediate planar surface is disposed at a known        angle with respect to a feature of the receiving element.        Item 50. The optical ferrule of any of items 42 through 49,        wherein the receiving element is a groove and the receiving        element feature is the bottom of the groove.        Item 51. The optical ferrule of item 50, wherein the groove is a        U or V-shaped groove.        Item 52. The optical ferrule of item 50, wherein the        intermediate surface is parallel with the feature of the        receiving element.        Item 53. The optical ferrule of any of items 42 through 52,        wherein the receiving elements and the light affecting elements        are disposed on a first side of the optical ferrule and further        comprising a planar mating surface disposed on a second side of        the optical ferrule opposite the first side.        Item 54. The optical ferrule of item 53, wherein the planar        mating surface is parallel to the feature of the receiving        element.        Item 55. The optical ferrule of item 54, wherein the receiving        element is a groove and the feature is the bottom of the groove.        Item 56. The optical ferrule of item 55, wherein the groove is a        U or V-shaped groove.        Item 57. The optical ferrule of item 55, wherein the groove is a        Y-shaped groove.        Item 58. The optical ferrule of item 53, wherein the second side        further comprises an optical window configured to transmit the        light out of the optical ferrule, wherein forward and rear        portions of the planar mating surface are disposed on either        side of the optical window.        Item 59. The optical ferrule of item 58, wherein at least one of        the forward and rear regions of the planar mating surface is        optically transparent.        Item 60. The optical ferrule of any of items 42 through 59,        further comprising at least one fiducial corresponding to at        least one of the light affecting element and the receiving        element.        Item 61. The optical ferrule of any of items 42 through 60,        further comprising at least a first fiducial corresponding to        the light affecting element and at least a second fiducial        corresponding to the receiving element.        Item 62. The optical ferrule of any of items 42 through 61,        wherein the optical ferrule includes a plurality of light        affecting elements and a plurality of receiving elements and        further comprising at least one fiducial corresponding to at        least one of the plurality of light affecting elements.        Item 63. The optical ferrule of any of items 42 through 62,        wherein the optical ferrule includes a plurality of light        affecting elements and a plurality of receiving elements and        further comprising at least one fiducial corresponding to at        least one of the plurality of receiving elements.        Item 64. The optical ferrule of items 42 through 63, wherein the        optical ferrule includes a plurality of light affecting elements        and a plurality of receiving elements and further comprising one        or more fiducials corresponding to each of the plurality of        receiving elements and one or more fiducials corresponding to        each of the plurality of light affecting elements.        Item 65. An optical ferrule comprising:

one or more receiving elements, each receiving element configured forreceiving and securing an optical waveguide; and

one or more light affecting elements, each light affecting elementcomprising:

-   -   a light redirecting feature comprising:        -   a curved lens in an optical path of light from the optical            waveguide, the receiving element configured to align the            waveguide with the lens; and        -   a planar region at least partially surrounding the lens the            planar region comprising a first reference surface for the            lens,            wherein the first reference surface is disposed at an angle            with respect to a second reference surface of the optical            ferrule that determines a positional relationship between            the lens and the waveguide.            Item 66. The optical ferrule of item 65, wherein the            receiving element comprises a groove and the second            reference surface is the bottom of the groove.            Item 67. The optical ferrule of item 66, wherein the groove            is a V-shaped or U-shaped groove.            Item 68. The optical ferrule of item 66, wherein the groove            is a Y-shaped groove.            Item 69. The optical ferrule of any of claims 65 through 68,            wherein variation in the angle is controlled to less than            +/−3 degrees.            Item 70. The optical ferrule of any of items 65 through 68,            wherein the variation in the angle is controlled to less            than +/−0.3 degrees.            Item 71. The optical ferrule of any of items 65 through 68,            wherein variation in the angle is controlled to less than            +/−0.03 degrees.            Item 72. The optical ferrule of any of items 65 through 68,            wherein variation in the angle is controlled to less than            +/−0.003 degrees.            Item 73. The optical ferrule of any of items 65 through 68,            wherein variation in the angle is controlled to less than            +/−0.0003 degrees.            Item 74. The optical ferrule of any of items 65 through 73,            wherein the light affecting element includes an intermediate            surface that extends between the receiving element and the            light affecting element and the intermediate surface            comprises the second reference surface.            Item 75. The optical ferrule of any of items 65 through 74,            wherein the receiving elements and the light affecting            elements are disposed on a first side of the optical ferrule            and further comprising a planar surface disposed on a second            side of the optical ferrule opposite the first side and the            planar surface comprises the second reference surface.            Item 76. The optical ferrule of item 75, wherein the second            side further comprises an optical window configured to            transmit the light out of the optical ferrule, wherein            forward and rear portions of the planar mating surface are            disposed on either side of the optical window.            Item 77. The optical ferrule of item 75, wherein at least            one of the forward and rear regions of the planar mating            surface is optically transparent.            Item 78. The optical ferrule of any of items 65 through 77,            further comprising at least one fiducial corresponding to at            least one of the light affecting element and the receiving            element.            Item 79. The optical ferrule of any of items 65 through 78,            further comprising at least a first fiducial corresponding            to the light affecting element and at least a second            fiducial corresponding to the receiving element.            Item 80. The optical ferrule of any of items 65 through 79,            wherein the optical ferrule includes a plurality of light            affecting elements and a plurality of receiving elements and            further comprising at least one fiducial corresponding to at            least one of the plurality of light affecting elements.            Item 81. The optical ferrule of any of items 65 through 80,            wherein the optical ferrule includes a plurality of light            affecting elements and a plurality of receiving elements and            further comprising at least one fiducial corresponding to at            least one of the plurality of receiving elements.            Item 82. The optical ferrule of any of items 65 through 81,            wherein the optical ferrule includes a plurality of light            affecting elements and a plurality of receiving elements and            further comprising one or more fiducials corresponding to            each of the plurality of receiving elements and one or more            fiducials corresponding to each of the plurality of light            affecting elements.            Item 83. The optical ferrule of any of items 65 through 82,            wherein the first reference surface provides a local            reference for the lens.            Item 84. An injection mold comprising:

a first mold side and a second mold side that fit together to define acavity for molding a unitary optical ferrule, the cavity configured toseparate along a parting axis, the unitary optical ferrule being moldedwith a thickness axis parallel to the parting axis, the first mold sidehaving mold features configured to mold:

one or more light affecting elements, each light affecting elementcomprising:

a light redirecting feature comprising:

a curved lens in an optical path of light from the optical waveguide,the receiving element configured to align the waveguide with the lens;and

a planar region at least partially surrounding the lens and comprising afirst reference surface for a position of the lens,

wherein the first reference surface is disposed at an angle with respectto a second reference surface of the optical ferrule that determines apositional relationship between the lens and the waveguide.

Item 85. The injection mold of item 84, wherein the receiving elementcomprises a groove and the second reference surface is the bottom of thegroove.

Item 86. The injection mold of item 85, wherein the groove is a V-shapedor U-shaped groove. Item 87. The injection mold of item 85, wherein thegroove is a Y-shaped groove.

Item 88. The injection mold of item 84, wherein variation in the angleis controlled to less than +/−3 degrees.

Item 89. The injection mold of item 84, wherein the variation in theangle is controlled to less than +/−0.3 degrees.

Item 90. The injection mold of item 84, wherein variation in the angleis controlled to less than +/−0.03 degrees.

Item 91. The injection mold of item 84, wherein variation in the angleis controlled to less than +/−0.003 degrees.

Item 92. The injection mold of item 84, wherein variation in the angleis controlled to less than +/−0.0003 degrees.

Item 93. The injection mold of any of items 84 through 92, wherein thelight affecting element includes an intermediate surface that extendsbetween the receiving element and the light affecting element and theintermediate surface comprises the second reference surface.Item 94. The injection mold of items 84 through 93, wherein thereceiving elements and the light affecting elements are disposed on afirst side of the optical ferrule and further comprising a planarsurface disposed on a second side of the optical ferrule opposite thefirst side and the planar surface comprises the second referencesurface.Item 95. The injection mold of item 94, wherein the second side furthercomprises an optical window configured to transmit the light out of theoptical ferrule, wherein forward and rear portions of the planar matingsurface are disposed on either side of the optical window.Item 96. The injection mold of item 95, wherein at least one of theforward and rear regions of the planar mating surface is opticallytransparent.Item 97. The injection mold of any of items 84 through 96, wherein thefirst mold side includes at least one mold feature configured to mold atleast one fiducial corresponding to at least one of the light affectingelement and the receiving element.Item 98. The injection mold of any of items 84 through 97, wherein thefirst mold side includes at least one mold feature configured to mold atleast a first fiducial corresponding to the light affecting element andat least one mold feature configured to mold at least a second fiducialcorresponding to the receiving element.Item 99. The injection mold of any of items 84 through 98, wherein moldfeatures are configured to mold a plurality of light affecting elements,a plurality of receiving elements and at least one fiducialcorresponding to at least one of the plurality of light affectingelements.Item 100. The injection mold of any of items 84 through 99, wherein themold features are configured to mold a plurality of light affectingelements, a plurality of receiving elements and at least one fiducialcorresponding to at least one of the plurality of receiving elements.Item 101. The injection mold of any of items 84 through 100, wherein themold features are configured to mold a plurality of light affectingelements, a plurality of receiving elements, one or more fiducialscorresponding to each of the plurality of receiving elements, and one ormore fiducials corresponding to each of the plurality of light affectingelements.Item 102. The injection mold of any of items 84 through 101, wherein thefirst reference surface provides a local reference for the lens.

Unless otherwise indicated, all numbers expressing feature sizes,amounts, and physical properties used in the specification and claimsare to be understood as being modified in all instances by the term“about.” Accordingly, unless indicated to the contrary, the numericalparameters set forth in the foregoing specification and attached claimsare approximations that can vary depending upon the desired propertiessought to be obtained by those skilled in the art utilizing theteachings disclosed herein. The use of numerical ranges by endpointsincludes all numbers within that range (e.g. 1 to 5 includes 1, 1.5, 2,2.75, 3, 3.80, 4, and 5) and any range within that range.

Various modifications and alterations of the embodiments discussed abovewill be apparent to those skilled in the art, and it should beunderstood that this disclosure is not limited to the illustrativeembodiments set forth herein. The reader should assume that features ofone disclosed embodiment can also be applied to all other disclosedembodiments unless otherwise indicated. It should also be understoodthat all U.S. patents, patent applications, patent applicationpublications, and other patent and non-patent documents referred toherein are incorporated by reference, to the extent they do notcontradict the foregoing disclosure.

The invention claimed is:
 1. A molded unitary optical ferrule comprisinga molded first section molded by a first side of a mold, an oppositemolded second section molded by an opposite, second side of the mold,and a parting line artifact formed on a surface of the molded unitaryoptical ferrule and separating the first and second sections alongsubstantially an external perimeter of the molded unitary opticalferrule, the first section comprising at least one first alignmentfeature, and a light affecting element for affecting one or more of adirection and a divergence of light propagating within the moldedunitary optical ferrule, the affected light exiting the molded unitaryoptical ferrule through an output surface thereof, the second sectioncomprising the output surface, such that when the molded unitary opticalferrule is mated with a mating ferrule along a mating axis, the at leastone first alignment feature controls a translation of the molded unitaryoptical ferrule along a lateral axis orthogonal to the mating andthickness axes, and a rotation of the molded unitary optical ferrulearound the thickness axis.
 2. The molded unitary optical ferrule ofclaim 1, wherein at least the output surface is coated with an opticalantireflection coating.
 3. The molded unitary optical ferrule of claim1, wherein the second section further comprises at least one secondalignment feature.
 4. The molded unitary optical ferrule of claim 3,wherein the second alignment feature comprises at least one planarsurface.
 5. The molded unitary optical ferrule of claim 4, wherein theat least one planar surface is a single planar surface.
 6. The moldedunitary optical ferrule of claim 4, wherein the at least one planarsurface are multiple parallel planar surfaces.
 7. The molded unitaryoptical ferrule of claim 4, wherein the at least one planar surface aremultiple coplanar surfaces.
 8. The molded unitary optical ferrule ofclaim 4, wherein, during mating, the at least one planar surface slideson a planar surface of a mating ferrule.
 9. The molded unitary opticalferrule of claim 4, wherein the at least one planar mating surfacecomprises a plurality of lands between a plurality of grooves.
 10. Themolded unitary optical ferrule of claim 1, further comprising one ormore elements configured for receiving and securing an opticalwaveguide.
 11. The molded unitary optical ferrule of claim 10, whereinthe light propagating within the molded unitary optical ferrule isemitted by or received by one or more optical waveguides secured by theone or more elements configured for receiving and securing the opticalwaveguide of the molded unitary optical ferrule.